Installing Rear Spring Strut (Air Springs)

Information 

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Dimension X - lower edge of wing to center of axle (shown as an example)

• All screws and bolts on the axle must be tightened in vehicle position. Vehicle position means: vehicle standing on its wheels, or the wheel suspension is raised with a universal vehicle lift. Dimension -X- , from lower edge of wing to center of axle corresponds to vehicle position. For the current height values, please refer to the adjustment values for suspension alignment 

  > 4495TW ADJUSTMENT VALUES FOR SUSPENSION ALIGNMENT .

• Visually inspect all parts. 
• Replace self-locking nuts. 
• Replace all expansion screws (screws fitted using torque angle tightening procedure). 
• Use correct tightening torques and torque angle. 

  > 4X00IN TIGHTENING TORQUES FOR REAR AXLE

Information 

• When working on the air-spring strut, make sure that the air-spring strut does not become twisted. 
• The air-spring struts are pre-filled to approx. 2.5 bar overpressure ex-works. If a new air-spring strut is installed, air can diffuse (escape) from the bellows of the air-spring strut as a result of storage times of varying duration. If the air-spring strut is removed from the transport packaging and installed without being filled, the bellows can fall into folds, thereby damaging the air-spring strut. For this reason, all air-spring struts must be re-filled prior to use. The procedure is described in detail in the course of the repair instructions. 

  >4301IN FILLING SPECIFICATION FOR AIR-SPRING STRUT 

Information 

• Do not remove air-spring strut from transport packaging until it has been filled. This will prevent damage to the inner bellows. 
• During assembly work, make sure that there are no pressure marks on the protective boot of the air-spring strut. 

Information 

• The air-spring strut must only be filled with the approved gasses, nitrogen or oil-free compressed air. 
• In some cases, up to 11 bar overpressure (upper tolerance, spring strut depressurized) is required to open the pressure control valve. 
• Fill the air-spring strut using 3 to 4 shots of pressure. Filling the air with individual pressure shots will prevent the air-spring strut from being filled with too much overpressure. 
• Do not fill the air-spring strut with overpressure of more than 2.5 bar. 

Information 

• Check the torque at the pressure control valve. 

  > 4X00IN TIGHTENING TORQUES FOR LEVELLING SYSTEM/PORSCHE DYNAMIC CHASSIS CONTROL (PDCC)

Information 

The pictures shown in this document may differ from the original.

Information 

Always check for correct insertion depth of plug connections for the compressed air hoses:

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Checking color markings

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Checking dimension

• Only one color marking (one white ring) must be visible on the connection. 
• If two color markings (two white rings) are visible, the correct insertion depth has not been reached. 
• - The dimension -x- from the end of the compressed air hose to the push-on connector must be at least 8.0 mm. 

1. A new air-spring strut must be filled before it is fitted.

   >4301IN FILLING SPECIFICATION FOR AIR-SPRING STRUT 

   A second mechanic is needed for installing the spring strut. 

2. Only raise the vehicle as far as required on the lifting platform so that a suitable jack can fit under the wheel bearing housing and a second mechanic can easily reach the luggage compartment floor with a small ladder. > Upper spring-strut mount 
3. Carefully fit the spring strut -1-  at the upper spring-strut mount.
4. When doing so, make sure that the pins -3-  of the rocker bearing -2-  fit exactly into the corresponding bore -4-  on the body.

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   Upper spring-strut mount

5. Position the jack -2-  as a support under the spring strut -1-  and raise it as far as required -A-  until the installation position of the spring strut no longer changes.

   The rocker bearing must be flush with the body. 

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   Installing spring strut

6. A second mechanic -3-  must now climb onto a suitable pedestal -4-  or small ladder and fit and tighten the top screws -1-  on the spring strut. Final tightening of the top fastening screws to the specified tightening torque is done in Step 11.

   When fitting the screws, make sure that they do not tilt and can be screwed in easily.

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   Upper spring-strut mount

7. Lift the vehicle.
8. Insert the spring strut into the wheel bearing housing with the help of the jack.

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   Supporting the spring strut (shown as an example)

9. Fit the lower spring strut -1-  with the wheel bearing housing -2-  and connecting link -4-  .

   To do this, insert the fastening screw -3-  through the components from behind and fit it.

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   Spring strut screw (air springs)

10. Plug in electric plug connection -1-  for the spring strut -A-  and lock it -a-  .

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    Electric plug connection for rear spring strut (air springs)

11. Fit the pressure line -1-  to the pressure control valve -2-  using insert tool T10212 > T10212 - insert tool  ,

    > Tightening torques

    Then clip the pressure line into the retaining devices.

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    Pressure line for rear spring strut

12. Lower the vehicle.
13. Then fit the fastening screws -1-  for the upper spring strut to the specified tightening torque.

    The tightening sequence -A, B, C, D-  must be strictly observed!

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    Installation sequence for upper spring strut screws

14. Secure the caps -1-  on the top fastening screws for the spring strut at the front.

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Removing caps